Search Results (8)

Additive manufacturing is revolutionizing the production of thermo-fluidic devices by enabling the creation of a wide variety of complex architectures, significantly enhancing performance and efficiency. Nevertheless, the range of structural types investigated to date remains limited, with most studies employing simplified methodologies and constrained operating conditions. This study explores the thermo-hydraulic performance of water-cooled annular channels incorporating BCC, Octahedral, and gyroid structures fabricated from AISI 316L stainless steel using Laser Powder Bed Fusion. The samples were experimentally tested across a broad spectrum of mass flow rates using a custom-designed test rig to evaluate heat transfer and pressure loss performance, and extensive morphological characterization was conducted to correlate the thermo-fluid dynamic behavior with the geometric and surface features specific to the manufacturing process. The investigation revealed that reticular configurations are preferable when low pressure losses are required, whereas gyroids are more suitable for high thermal loads. The topology of the structures was shown to be a key factor influencing overall performance, emphasizing the importance of selecting the appropriate structure for each specific application and the significant potential for performance improvements through the development of tailored metamaterials. Full article

This research aims to determine the primary thermofluidic correlations describing the thermosiphon effect under idealized steady-state conditions, considering water-in-glass evacuated-tube geometry, tilt angle, and heat flux. A numerical model based on Computational Fluid Dynamics (CFD) was developed to obtain these correlations for water-in-glass evacuated-tube solar collectors. Initial validation against experimental velocity and temperature profiles was necessary. With a validated CFD model, thermofluidic correlations were determined, expressed as dimensionless parameters such as Re, Gr, and Pr, water-in-glass evacuated-tube dimensions, and tilt angle. Symmetry was exploited in the water-in-glass evacuated-tube geometry for both validation simulations and the development of thermofluidic correlations. Contrary to correlations recorded in the literature, the correlations obtained in this study indicate an increase in water flow and a decrease in mean temperature with increasing tilt angle. These correlations are crucial for the energy–exergy balance formulations used in the analysis and design of such thermal systems. Full article

To improve machining processes concerning the usage of lubricants, knowledge of the thermo-mechanical and thermo-fluid interactions at the cutting zone is of great importance. This study focuses on the description of the convective heat transfer which occurs during circular sawing when the lubricant is provided via an internal coolant supply. The highly complex flow field inside the cavity of the sawing process is separated into two distinct flow forms, an impingement and a channel flow. With the aid of experimental and numerical studies, the heat transfer characteristics of these two flow forms have been examined for water and a lubricant used in the circular sawing process. Studies have been conducted over a wide range of Reynolds numbers (impingement flow: $2\times {10}^3<\mathrm{Re}<17\times {10}^3$, channel flow: $1\times {10}^3<\mathrm{Re}<30\times {10}^3$). Additionally, the variation in the inlet temperature of the fluid, as well as the variation in heating power, has been studied. Overall, the impingement flow yields a significantly higher heat transfer than the channel flow with Nußelt-numbers ranging from 120 to 230, whereas the Nußelt-numbers in the case of the channel flow range from 20 to 160. For both flow forms, the use of the lubricant results in a better heat transfer compared with the usage of water. With the aid of these studies, correlations to describe the heat transfer have been derived. The provided correlations are to be used in a coupled numerical model of the chip formation process which also includes the effects of the heat transfer to the coolant lubricant. Full article

Accuracy of temperature measurement of natural gas flows in closed conduits is a highly debated topic due to the complexity of the measurement chain and the related economic impact. First, specific thermo-fluid dynamic issues occur because of the difference between the temperature of the gas stream and that of the external ambient and the mean radiant temperature inside the pipe. Furthermore, the installation conditions of the temperature sensor (e.g., immersion length and diameter of the thermowell) play a crucial role. In this paper, the authors present the results of a numerical and experimental study conducted both in the laboratory and in-field aimed at analyzing the reliability of temperature measurement in natural gas networks as a function of the pipe temperature and of the pressure and velocity of the gas stream. The results obtained in the laboratory show errors ranging between 0.16 and 5.87 °C in the summer regime and between −0.11 and −2.72 °C in the winter regime, depending on the external pipe temperature and gas velocity. These errors have been found to be consistent with those measured in-field, where high correlation between the pipe temperatures, the gas stream and the external ambient have been also demonstrated, especially in summer conditions. Full article

Microstructure evolution in metal additive manufacturing (AM) is a complex multi-physics and multi-scale problem. Understanding the impact of AM process conditions on the microstructure evolution and the resulting mechanical properties of the printed component remains an active area of research. At the meltpool scale, the thermo-fluidic governing equations have been extensively modeled in the literature to understand the meltpool conditions and the thermal gradients in its vicinity. In many phenomena governed by partial differential equations, dimensional analysis and identification of important dimensionless numbers can provide significant insights into the process dynamics. In this context, we present a novel strategy using dimensional analysis and the linear least-squares regression method to numerically investigate the thermo-fluidic governing equations of the Laser Powder Bed Fusion AM process. First, the governing equations are solved using the Finite Element Method, and the model predictions are validated by comparing with experimentally estimated cooling rates, and with numerical results from the literature. Then, through dimensional analysis, an important dimensionless quantity interpreted as a measure of heat absorbed by the powdered material and the meltpool, is identified. This dimensionless measure of absorbed heat, along with classical dimensionless quantities such as Péclet, Marangoni, and Stefan numbers, are employed to investigate advective transport in the meltpool for different alloys. Further, the framework is used to study variations in the thermal gradients and the solidification cooling rate. Important correlations linking meltpool morphology and microstructure-evolution-related variables with classical dimensionless numbers are the key contribution of this work. Full article

An experimental study regarding the thermofluid characteristics of a shell-and-plate heat exchanger with different chevron angles (45°/45°, 45°/65°, and 65°/65°) with a plate diameter of 440 mm was carried out. Water was used as the working fluid on both sides and the corresponding temperatures ranged from 30–70 °C. The flow rate on the plate or shell side ranged from 10–60 m³/h. The effects of chevron angles on the heat transfer and fluid flow characteristics of shell-and-plate heat exchangers were studied in detail. With regard to the heat transfer performance on the plate side, a higher chevron angle (65°/65°) resulted in a significantly better performance than a low chevron angle (45°/45°). The effect of the chevron angle became even more pronounced at high Reynolds numbers. Unlike the plate side, an increase in the chevron angle had a negative effect on the heat transfer performance of the shell side. Additionally, this opposite effect was more prominent at low Reynolds numbers due to the comparatively large contribution of the manifold. The friction factor increased appreciably with the increase in the chevron angle. However, when changing the chevron angle from 45°/45° to 65°/65°, the increase in the friction factor was about 3–4 times on the plate side while it was about 2 times on the shell side. This can be attributed to the presence of the distribution/collection manifold on the shell side. Empirical correlations for the Nusselt number and friction factor were developed for different combinations of chevron angles with mean deviations of less than 1%. Full article

The work focuses on the development of a thermo-fluid dynamic simulation model of a section of close cooling, called a jet cooler, inserted in the galvanizing line of metal band production. Two models of increasing accuracy have been tested and calibrated by experimental data. Special attention to turbulence modeling and boundary conditions has been given. A literature survey was focused on the jet impingement process (the reference heat transfer mechanism for the system component) and on available correlations to predict the heat exchange coefficient. The numerical simulation of jet impingement has been applied to a module of an actual industrial cooler for steel band production. The operation of the jet cooler was simulated in real operating conditions to get a detailed insight into the jet impingement mechanism in order to optimize the heat transfer and reduce, as far as possible, the cooling fluid mass flow rate. The comparison of heat transfer correlations, used in industrial preliminary design, with detailed CFD results is discussed. Full article

Integrated microchannel cooling is a very promising concept for thermal management of 3D ICs, because it offers much higher cooling performance than conventional forced-air convection. The thermo-fluidic simulations of such chips are usually performed using a computational fluid dynamics (CFD) approach. However, due to the complexity of the fluid flow modelling, such simulations are typically very long and faster models are therefore considered. This paper demonstrates the advantages of TIMiTIC—a compact thermal simulator for chips with liquid cooling—and shows its practical usefulness in design space exploration of 3D ICs with integrated microchannels. Moreover, thermal simulations of a 3D processor model using the proposed tool are used to estimate the optimal power dissipation profile in the chip and to prove that such an optimal profile allows for a very significant (more than 10 °C) peak temperature reduction. Finally, a custom correlation metric is introduced which allows the comparison of the power distribution profiles in terms of the peak chip temperature that they produce. Statistical analysis of the simulation results demonstrates that this metric is very accurate and can be used for example in thermal-aware task scheduling or dynamic voltage and frequency scaling (DVFS) algorithms. Full article